Organic field-effect transistor, method for structuring an OFET and integrated circuit

ABSTRACT

The invention relates to an organic field-effect transistor, to a method for structuring an OFET and to an integrated circuit with improved structuring of the functional polymer layers. The improved structuring is obtained by introducing, using a doctor blade, the functional polymer in the mold layer in which recesses are initially produced by imprinting.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a 371 of PCT/DE01/04611 filed Dec. 7, 2001 which claims the benefit of Germany Application No. 100 61 297.0, filed Dec. 8, 2000, the contents of which are hereby incorporated herein by reference in their entirety.

FIELD OF THE INVENTION

The invention relates to an organic field-effect transistor, to a method for patterning an OFET and to an integrated circuit with improved patterning of the functional polymer layers.

BACKGROUND OF THE INVENTION

Organic integrated circuits (integrated plastic circuits) based on organic field-effect transistors (OFETs) are used for high-volume microelectronics applications and disposable products such as identification and product “tags”. A “tag” is, for example, an electronic bar code such as is applied to goods or suitcases. OFETs have a wide range of applications as RFID tags (radio frequency identification tags) which do not necessarily have to be attached only on the surface. With OFETs for these applications, there is no requirement for the excellent operating characteristics offered by silicon technology; on the other hand there should be a guarantee of low manufacturing costs and mechanical flexibility. The components such as electronic bar codes are typically single-use products and are only of interest economically if they can be produced in low-cost processes.

Previously, due to the manufacturing costs, only the conductor layer of the OFET was patterned. The patterning can only be effected via a two-stage process (“Lithography method”, cf. Applied Physics Letters 73(1), 1998, pp. 108-110 and Mol. Cryst. Liq. Cryst. 189, 1990, pp. 221-225) with initially full-area coating and subsequent patterning, which is furthermore material-specific. By “material specificity” is meant that the described process with the cited photochemical components only works on the conducting organic material polyaniline. A different conducting organic material, e.g. polypyrrole, cannot be patterned as a matter of course by this means.

The lack of patterning of the other layers, such as at least that of the semiconducting and insulating layers composed of functional polymers, leads to a marked lowering in performance of the OFETs obtained, but this is still dispensed with for reasons of cost. The patterned layer can be patterned using other known methods (such as e.g. printing) only in such a way that the length 1, which denotes the distance between source and drain electrode and therefore represents a measure for the performance density of the OFET, is at least 30 to 50 μm. The aim is to achieve lengths 1 of less than 10 μm, however, which means that at the present time, with the exception of the complex and expensive lithography method, no patterning method appears practicable.

SUMMARY OF THE INVENTION

The object of the invention is therefore to provide a low-cost method for patterning high-resolution OFETs that is suitable for mass production. It is further the object of the invention to create a more powerful, because comprising more patterned layers, as well as a more compact OFET which can be fabricated with a smaller distance 1.

The subject matter of the invention is an organic field-effect transistor (OFET) comprising at least the following layers on a substrate:

-   -   an organic semiconductor layer between and over at least a         source and at least a drain electrode which are made of a         conducting organic material,     -   an organic insulation layer over the semiconducting layer and     -   an organic conductor layer         where the conductor layer and at least one of the two other         layers are patterned. Also the subject matter of the invention         is a method for patterning an OFET by introducing at least one         functional polymer into a negative mold by means of a doctor         blade. Finally, the subject matter of the invention is an         integrated circuit comprising at least one OFET which has at         least one patterned conductor layer and one further patterned         layer.

A negative mold is a term used to denote a patterned layer or a part of a patterned layer which contains recesses into which the functional polymer, which forms, for example, an electrode of an OFET or a semiconductor or an insulator layer, is introduced by means of a doctor blade.

The method comprises the following operating steps:

-   a) a possibly full-area mold layer, which does not have to be     limited to the area that is to be patterned, is applied to a     substrate or a lower layer. This mold layer is not the functional     polymer (that is, semiconducting, conducting or insulating layer)     but a different organic material which serves as a mold or template     for the conducting organic electrode layer. This other organic     material should have insulating properties. -   b) the mold layer is provided with recesses which correspond to the     patterns by means of imprinting (impressing of a stamp die with     subsequent curing by exposure), -   c) the functional polymer is then introduced by means of a doctor     blade into these recesses in liquid form, as a solution and/or as a     molten mass.

The negative mold of the pattern on the mold layer can be generated by the imprint method, which represents a mature technology in the field of electronic and microelectronic components, on the substrate or on a lower layer. The material of the negative mold may be a UV-curable resist which has recesses following imprinting and exposure.

Resists suitable for this are available commercially and the method of patterning them by imprinting is known in the literature. Generally, during the imprinting onto the uncured mold polymer, which is deposited as a layer on the substrate or a lower layer, a stamp is impressed in such a way that recesses are created in the same manner as the patterning is to take place. The layer provided with recesses is then cured either thermally or by irradiation, which results in the rigid mold layer into which the functional polymer can be introduced by means of a doctor blade.

The advantage of the doctor blade method is that the difficult process of patterning functional polymers is prepared by means of the established and proven imprint method. This means that a rich technical background is available as a reference source and extremely fine patterns can be achieved. Furthermore, the doctor blade method is not material-specific. To the contrary, the doctor blade method enables polyaniline, but also any other conducting organic material, such as e.g. polypyrrole, to be used for the production of electrodes. Similarly, it allows any other organic material, such as e.g. polythiophene as a semiconductor and/or polyvinylphenol as an insulator, to be applied by means of a doctor blade and therefore patterned, i.e. the entire OFET.

According to an embodiment of the method, the negative mold is removed upon completion of the curing of the functional polymer, thereby reducing any height difference between functional polymer and negative mold possibly caused by evaporation of the solvent or shrinkage.

Another approach to avoiding any height difference which may have arisen between negative mold and functional polymer is to repeat the doctor blade application process, which results in the volume of the negative mold simply being filled up further.

As a rule, the functional polymers can largely be left at their optimal consistency. Thus, for example, polyaniline as a conducting organic material possesses a certain viscosity at its optimal conductivity. If, for example, polyaniline is to be printed and not applied by doctor blade, its viscosity must be set to a value appropriate to the printing method. This usually means that the conductivity is impaired. For the doctor blade method, the viscosity margin is incomparably greater than for printing, with the result that no changes to the viscosity usually have to be made to the organic material.

Finally, an advantage of the doctor blade method is the capability to apply thick layers. Thus, for example, the conductivity of 1 μm-thick polymer electrodes is effectively higher than with a typically 0.2-μm layer thickness. An OFET with a layer thickness in the region of up to 1 μm, particularly in the range from 0.3 to 0.7 μm, is therefore advantageous.

The term “functional polymer” as used here denotes any organic, organometallic and/or inorganic material which is integrated as a functional component in the structure of an OFET and/or an integrated circuit composed of a plurality of OFETs. This includes, for example, the conducting component (e.g. polyaniline) which forms an electrode, the semiconducting component which forms the layer between the electrodes, and the insulating component. It should be explicitly pointed out that the description “functional polymer” accordingly also encompasses non-polymer components such as, for example, oligomeric compounds.

Briefly, the term “organic” as used here designates anything which is “based on organic material”, the term “organic material” encompassing all types of organic, organometallic and/or inorganic synthetic materials generally referred to in English as e.g. “plastics”. This includes all kinds of materials with the exception of the traditional semiconductors (germanium, silicon) and the typical metallic conductors. Any limitation in the dogmatic sense to organic material as carbon-containing material is accordingly not intended. Indeed, consideration is also given to the widespread use of e.g. silicons. Furthermore, the term is not intended to be subject to any limitation to polymer or oligomeric materials, but rather the use of “small molecules” is also entirely conceivable.

The term “lower layer” as used here refers to any layer of an OFET onto which a layer that is to be patterned is applied. The mold layer from the mold polymer joins up with the “lower layer” or the substrate. Here, the mold polymer is also not fixed by the designation “polymer” to a polymer aggregate state; rather, this substance may also be any practically usable plastic material for forming a negative mold.

BRIEF DESCRIPTION OF THE DRAWINGS

An embodiment of the method is explained in more detail in the following description with reference to schematic figures.

FIG. 1.1 shows the substrate or a lower layer 1 onto which the mold layer of the negative mold 2, for example composed of a mold polymer such as a UV-curable resist, is applied over the full area. The mold layer 2 is provided with recesses by means of a stamping die 4, such as is shown in FIG. 1.2. In other words, recesses are impressed into the mold layer 2 by means of the die 4, which can be composed, for example, of silicon dioxide (SiO₂). While the die 4 impresses the recesses 12, the mold layer 2 is irradiated with UV light, as a result of which the mold polymer 2 cures as the recesses 12 are permanently formed. This produces the recesses 12 in the mold layer 2, as shown in FIG. 1.3. On completion of the stamping, the die 4 is withdrawn from the mold layer 2. The functional polymer 8 (e.g. polyaniline) is then introduced into the recesses 12 by means of a doctor blade 9 (FIG. 1.4.). In FIG. 1.5. it can be seen how the functional polymer 8 fills out the recesses 12 of the mold layer 2 in the finished OFET.

FIG. 2 shows a further embodiment of the method using a continuous process or continuous web printing. The belt consisting of substrate or lower layer 1 can be seen with the mold polymer 2, which may be a UV-curable but also a thermally curable resist. This belt is now subjected to different operating steps as it travels from left to right, as indicated by the arrow 13, along multiple pressure rollers 10. First, it passes the shadow plate 3, by means of which the not yet cured mold polymer 2 is protected against radiation. Then, recesses are impressed in the mold polymer 2 with the aid of the die roller 4 and are simultaneously hardened by means of the UV lamp 5 integrated in the die roller 4. The arrow emanating from 5 indicates the direction of the light cone which is emitted by 5. The belt provided with recesses 12 in the mold layer 2 then passes under a UV lamp or heater 6 for post-curing, with the result that a patterned resist 7 is produced. In the patterned resist 7 with the recesses 12, the functional polymer 8 is then introduced by means of the doctor blade 9, thereby producing the finished pattern 11. 

1. Method for forming an OFET comprising the following: a) depositing a mold layer for a negative mold on a substrate or a lower layer, b) imprinting recesses into the mold layer whereby the recesses correspond to the negatives of subsequent patterns of the OFET and c) then introducing a functional polymer into the recesses by a doctor blade.
 2. Method according to claim 1, wherein the mold layer is removed upon completion of the patterning.
 3. Method according to claim 1, wherein the functional polymer is introduced at least twice into the recesses of the mold layer by the doctor blade.
 4. Method according to claim 1, comprising continuously performing the method of claim 1 with a continuously running belt.
 5. Method according to claim 2, wherein the functional polymer is introduced at least twice into the recesses of the mold layer by the doctor blade.
 6. Method according to claim 2, comprising continuously performing the method of claim 2 with a continuously running belt.
 7. Method according to claim 3, comprising continuously performing the method of claim 3 with a continuously running belt. 